High speed manipulation of non-uniform objects

ABSTRACT

System and methods for manipulating and sorting of objects being moved along a conveyor are disclosed, whereby control of the object is achieved through the application of one or more of vacuum, impaling, or mechanical grasping. One embodiment is directed to a robotic arm and vision detection system operable for detecting a target object to be grasped from a stream of objects being moved on a conveyor, and moving a suction head into position over the target object that has been detected on the conveyor, the suction head having a flexible cup section disposed at a distal end thereof, the vacuum item pick-up system/method using high subsonic air flow (e.g., on the order of 60 scfm or more) through a suction cup having a flow opening area large enough that an airflow of 60 scfm does not result in an airspeed exceeding Mach 0.2 under standard conditions of temperature and pressure, and further having a flow opening area whose ratio to cup opening area falls between 0.36 and 1.44 for applying a desired vacuum suction force for grasping the target object. Either as a primary grasping mechanism, or as an optional supplemental grasping mechanism, a piercing mechanism may be inserted into the object and used to manipulate the object in space. Alternate systems/methods for manipulating and sorting objects via hitting, flicking, or pushing are also disclosed.

RELATED APPLICATION DATA

This application is a divisional of and claims the benefit under 35U.S.C. § 121 of U.S. patent application Ser. No. 15/946,627 (now U.S.Pat. No. 10,668,630) filed Apr. 5, 2018, which is a non-provisional ofand claims the benefit under 35 U.S.C. § 119(e) of U.S. ProvisionalPatent Application No. 62/548,817 filed Aug. 22, 2017, the disclosuresof which are incorporated by reference herein in their entireties.

BACKGROUND

The field of the present invention relates to a robotic system androbotic end-effector, and more particularly to one capable of high speedmanipulation of objects with variable or undefined shape, structure, orsize.

In the realm of robotic pick-and-place applications there has been acentral focus on performing well-defined, repeatable tasks. Thisparadigm is fundamentally predictable and specific. Classicalcomputation is adept at processing a precise list of instructions. As aresult, technologies have been developed for a narrow range ofapplications allowing for the interaction with the real world. One suchsubset is robotic end-effectors for manipulation of objects. An examplemay be found in food handling applications. Although small variationsmay exist, the rules for any given operation tend to be very precise andthe target object is well-defined. Pick-and-place grasping can be foundin numerous industries, but commodity-based grasping is typicallydesigned to leave no trace of handling. Applications exist wheredestructive methods of grasping can be utilized, one such field is wastehandling.

Increases in computation power has led to the expansion of deep learningalgorithms. In this paradigm the computer program is much more abstractand the inputs are no longer discrete, such as image recognition.Advancements in this field have numerous industrial applications. Onesuch industry is recycling, the sorting of recycled materials. Thenature of recycling is unpredictable with materials varying largely byregion and have extreme variations even within that subset. Themechanical component of the robotic system is becoming a limiting factorof these robotic systems. The present inventors have recognized thatsimilar to the shift in software, mechanical technologies need bedeveloped to interact with objects of unpredictable size, shape,orientation, and composition.

SUMMARY

The embodiments described herein are directed to material handlingsystems, or more specifically, robotic arm sorting systems and methodsof sorting, and in one embodiment to a robotic arm sorting system withgrasping mechanism/end-effector design capable of reliablymanipulating/grasping non-uniform objects. Even objects of indeterminatesize, shape, orientation, and surface condition can be grasped andrelocated in a given space. This grasping functionality need not bedependent to the specific grasping point chosen by the graspingmechanism. The system may be suitable when miscellaneous objects ofindeterminate/varied shape and size are located in the vicinity of thetarget object and the working environment is not controlled forcleanliness, and/or where the preservation of the object's condition isirrelevant.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic of a vacuum sorting system according to anembodiment, and including a front elevation view of a suction cupembodiment positioned to manipulate a target object.

FIG. 2 is a front isometric view of an example robotic arm and vacuumhead section of the sorting system of FIG. 1 according to an embodiment.

FIG. 3 is a top isometric view of the system of FIG. 2 .

FIG. 4 is an enlarged isometric view of the vacuum head section of thesorting system of FIGS. 2-3 .

FIG. 5 is an isometric view of a suction cup according to an embodiment.

FIG. 6 is a front elevation view of the suction cup of FIG. 5 .

FIG. 7 is a cross-sectional view of the suction cup of FIG. 6 takenalong line 7-7.

FIG. 8 is a bottom plan view of the suction cup of FIGS. 5-7 .

FIG. 9 is an isometric view of a suction cup according to anotherembodiment.

FIG. 10 is a front elevation view of the suction cup of FIG. 9 .

FIG. 11 is a cross-sectional view of the suction cup of FIG. 10 takenalong line 11-11.

FIG. 12 is a bottom plan view of the suction cup of FIGS. 9-11 .

FIGS. 13-14 are diagrammatic views of an alternate object grasping headaccording to an embodiment using a piercing mechanism.

FIG. 15 is a diagrammatic view of an alternate object grasping headaccording to an embodiment using a combination suction head and piercingmechanism.

FIG. 16 is a diagrammatic front view of an alternate object graspinghead including a mechanical grasping prong, the prongs being in theopen, non-grasping position.

FIG. 17 is a diagrammatic front view of the grasping head of FIG. 16with the prongs being in the closed, grasping position.

FIG. 18 is a diagrammatic top view of the grasping head of FIG. 17 .

FIG. 19 is a diagrammatic front view of an alternate object graspinghead including a combination suction head with mechanical graspingprongs of FIGS. 16-18 .

FIGS. 20A, 20B, 20C illustrate another alternate system for manipulatingobjects.

FIGS. 21A, 21B, 21C illustrate another alternate system for manipulatingobjects.

FIG. 22A is a front elevation view of an alternate suction cup having asuction cup lip formed with radial sections fitted with pressurizedveins, the radial sections shown in a first position.

FIG. 22B is a front elevation view of the suction cup of FIG. 22A withthe radial sections shown in a second position.

DETAILED DESCRIPTION

Certain embodiments will now be described with reference to thedrawings. To facilitate description, any element numeral representing anelement in one figure will represent the same element in any otherfigure. It is noted that embodiments of the grabbing/end-effectormechanisms will be described with reference to a particular robotic armsystem, but it will be appreciated that details of the describedmechanisms may be applied in other any robotic arm systems or the like.

FIG. 1 is a schematic of a pneumatically-powered vacuum sorting system10 according to a first embodiment with FIGS. 2-3 being isometric viewsof the system of FIG. 1 integrated into a robotic arm system. The system10 is shown as in FIGS. 2-3 to comprise a robotic arm system including acontroller 70, an item detection device/system 71 (e.g., a vision systemor means for detecting) to see/detect the materials being transferredalong the conveyor 5, and artificial intelligence system to think andidentify target objects to be sorted. The robotic arm system comprises aplurality of pairs of robotic arms 74, 76 and 72, 73, and 78, 79. Viathe robotic arms 74, 76 and 72, 73, and 78, 79, the controller 70 isoperative to move and position the suction head 50 in three dimensionsto seek out and engage a selected target object, such as a plasticbottle 120 from a stream of objects being conveyed through a target zonevia a conveyor 5.

The system 10 may be described as a vacuum pick-up apparatus thatincludes a specially designed grasping mechanism/end effector, shown asa flexible suction cup unit 100 disposed on the distal end of a tube orpipe section 60 at the bottom of the suction head 50. The suction cupunit 100 is specially designed to provide a high vacuum air flowcapacity as will be described further below.

The system 10 is provided with high air flow vacuum pump system(comprising the means to applying a high subsonic vacuum air flow). Tomeet a desired high vacuum air flow, the system 10 may be constructedwith a dual vacuum pump system comprised of a first vacuum pump 12 and asecond vacuum pump 32 disposed in parallel. The first vacuum pump 12 isconnected via a first flexible hose 18 drawing air through the flexiblehose 18 and through a filter 16 and exhausting out through exhaust 14.The flexible hose 18 is connected via a hose barb 19 to a rigid hose 20which in turn is connected via a second hose barb 21 to a secondflexible hose section 22. The second flexible hose section 22 is thenconnected to vacuum connector/port 54 of the wye connector 52.

Similarly, on the other side, the second vacuum pump 32 is connected viaa second flexible hose 38 drawing air through the second flexible hose38 and through a filter 36 and exhausting out through exhaust 34. Thesecond flexible hose 38 is connected via a hose barb 39 to a rigid hose40 which in turn is connected via a second hose barb 41 to a secondflexible hose section 42. The second flexible hose section 42 is thenconnected to vacuum connector/port 56 of the wye connector 52.

The wye connector 52 is a multi-port connector/manifold which is shownin FIG. 4 as having the two vacuum line connectors/ports 54, 56 and ablower connector/port 57. The connectors 54, 56 and 57 (collectivelycomprising a multi-port distribution manifold) all provide for an openfluid connection for air flow through suction head 50 to the lower pipesection 60. The suction cup unit 100 is connected to the end of thelower pipe section 60 via a threaded fitting or connector 102 attachedto the top section of the suction cup unit 100. The blower connector 57is connected via a flexible hose 58 to a pressure source 59 such as anair blower or compressed air source. The pressure source 59, flexiblehose 58 and blower connector/port 57 are optional components, but mayprovide for enhanced releasing force for the object being grabbed.

Alternately, the vacuum air flow may be provided by a single vacuumpump, three (or more) vacuum pumps, or another suitable vacuum source orsources. It is noted that a vacuum pump may comprise any suitable devicethat draws a vacuum, such as a positive displacement vacuum pump, liquidring vacuum pump, momentum transfer vacuum pump, regenerative vacuumpump, a venturi vacuum pump, or other.

Following is an example method of grasping items, comprising the stepsof:

-   -   detecting, via a vision recognition system, a target object to        be grasped from a stream of objects being moved on a conveyor.    -   using the robotic arms 72-79 of the system 10 to position the        suction head 50 (and the suction cup unit 100) over or onto an        object 120 identified by the vision recognition system to be        sorted.    -   activating the vacuum pressure (vacuum pumps 12, 32) to apply a        vacuum lifting force into the suction cup unit 100 for grasping        the object 120.    -   using the robotic arms 72-79 to lift the object 120 and move it        over a bin or desired sorting location.    -   discontinuing the vacuum pressure (and thus deactivating the        lifting force) being applied and dropping/depositing the object        120 into the bin or other desired sorting location.    -   optionally applying positive pressure (by the pressure source        59) through the suction cup unit 100 to assist in releasing the        object 120. The positive pressure provides a positive releasing        force on the object 120. When the vacuum force is being applied        by the vacuum pumps 12, 32, the pressure source 59 is        disconnected/isolated, to allow the vacuum grasping force to be        applied through the suction cup unit 100.

As described below, in one embodiment, the vacuum pump system isoperable for applying a high vacuum flow rate of at least 60 scfm(standard cubic feet per minute) through the suction cup unit 100 of thesuction head 50 when the pick-up apparatus is free from grasping atarget object (i.e., no item is being grasped by the suction cup unit100).

FIGS. 5-8 illustrate details of an example suction cup unit 100according to a first embodiment. The suction cup unit 100 is comprisedof a flexible cup section 105 and a connector (inlet section) 102. Theconnector 102 includes internal female threads 103 (NPT) for connectingto a male-threaded end of the lower pipe section 60 (of FIGS. 1-4 ). Aflexible suction cup 105 is attached to the bottom portion of theconnector 102. The example flexible cup section 105 is formed withmultiple bellows sections, with the example in FIGS. 5-8 having a firstbellow 105 a and a second bellow 105 b and a suction cup lower lip 105c. Alternatively the flexible suction cup section 105 may be formed witha different number of bellows such as a single bellow, or three or fourbellows, or more bellows.

A cup screen element 110 is optionally provided and disposed within theflexible cup section 105, as shown in FIG. 7 disposed in the secondbellow 105 b. The screen 110 may be alternatively disposed in anothersuitable location.

The screen 110, which may be replaceable, may be integrated into theflexible cup section 105. The screen 110 is sized for the screening ofmaterials of a desired size that are small enough or pliable enough tobe suctioned into an inner chamber 107 of the flexible cup section 105,but are of such a size (or type, e.g., pliable) that would obstruct thevacuum system. The design of the screen 110 (e.g., the size of thehexagonal openings) is such as to maintain adequate (high) vacuum airflow and not become clogged by dirt and debris while promoting the fullgrasping functionality. Likewise, miscellaneous smaller items of certainsize that are not targeted, but are in the target area, are screened bythe screen 110 such that the flexible cup section 105 and any subsequentvacuum hoses 18, 38 do not become clogged with foreign objects, whileparticles of a given small size (that will not obstruct the vacuumsystem) are allowed to pass through the screen opening without cloggingthe screen 110 itself. The screen is sized to have openings large enoughto avoid disrupting the high vacuum flow rate but small enough to screenundesirably large (or alternately pliable) items from passing throughthe suction head. The optional pressure source 59 may optionally assistin removing miscellaneous items trapped by the screen 110, blowing thoseitems back out of the suction cup unit 100.

The optional foam lip unit 112 (of FIGS. 5-8 ) may be constructed of asuitable flexible (e.g., polymer) material such as open cell foam (e.g.,polyurethane open cell foam). The foam lip unit 112 is shown formed as acylindrical, donut-shaped form having (as shown in FIG. 8 ) an internalopening of a diameter F and an outer diameter G. The foam lip unit 112is attached to the bottom of the flexible cup section 105 (i.e., to thelower cup lip 105 c) via an adhesive or other suitable attachmentmechanism. The optional foam lip adhesive (or other attachmentmechanism) may be selected to allow for the foam lip to be removablyattachable (i.e., replaceable), thereby being replaced easily withoutdamaging or replacing the cup section.

The dual vacuum pumps 12, 32 connected to respective vacuum connectors54, 56 combine to provide for a desired high vacuum air flow throughlower pipe section 60 and the inner chamber 107 of the flexible cupsection 105.

FIGS. 9-12 illustrate an alternative suction cup unit 200 according to asecond embodiment comprised of a flexible cup section 205 and aninlet/connector 202. The connector 202 includes internal female threads203 (NPT) for connecting to a corresponding male threaded end of thepipe section 60 (of FIGS. 1-4 ). The flexible cup section 205 attachesto the bottom portion of the connector 202. The flexible cup section 205is similar to the prior embodiment of the flexible cup section 105 andincludes two bellows 205 a and 205 b and a lower lip 205 c. Unlike theprior embodiment, suction cup unit 200 is illustrated without theoptional foam lip element whereby contact with the object 120 (shown asa plastic bottle) is made directly by the lower lip 205 c. A high flowscreen 210 is shown integrated within an internal chamber 207 of thelower bellow 205 b the screen operating as described in the previousembodiment.

The flexible cup sections 105, 205 may be made of a suitable flexiblematerial such as a flexible polymer material, e.g. polyurethane, orcombinations thereof.

The design of the suction cup units may be directed to vacuum handling,that is, to create a low pressure to generate lift and holding force. Inan example scenario with the suction cup positioned above the object,this lifting and holding force is accomplished by creating contact withthe object and evacuating the air from above the contact area of theobject. In order to achieve the vacuum, more air should be evacuatedthrough the suction cup than is leaked through the area of contact. Thedesign of certain embodiments described herein may function byoptimizing these two aspects.

First, sealing the object and minimizing leaks into the vacuum chamberis fundamentally achieved by promoting maximum compliance of the suctioncup to the surface of the object. The suction cup may be configured tobe pressed against the target item without requirement of preserving thecondition of the item. A multi-bellow design may allow the flexible cupsection to articulate and align to non-orthogonal surfaces. In suctioncup unit 200, the soft lip 205 c that forms the base of suction cup unit200 is flexible so that it can conform to ridges on the object 120.Alternately, the optional foam unit 112 (shown attached to the bottom ofthe suction cup unit 100 of FIGS. 5-8 ) may be used at the point ofcontact to close off the smaller air gaps resulting from more subtle andcomplex variations in the surface of the object 120 (e.g., a plasticbottle) being grasped. Similarly, without the optional foam unit 112,the soft lip 105 c (of the suction cup unit 100) is flexible so that itcan conform to ridges on the object 120.

Second, the bore of the suction cup unit 100,200 is optimized to allowadequate (high) vacuum air flow. This high vacuum air flow capacity ofthe suction cup is provided to generate sufficient lift force whentargeting objects with highly irregular surfaces, even porous surfacesor those containing hole(s) can be grasped. The high vacuum air flowalso increases the rate of vacuum creation, which increases the speed inwhich an object is grasped.

The relative size of the flow opening area (determined by diameter A,A₁inlet flow opening 106,206) versus the area of the cup opening(determined by diameter D,D₁ of flexible cup section internal opening107,207) may be designed to maximize the lifting force for theapplication of grasping items of different/indeterminate size and shape.Suction/lifting force is a function of two variables: area and pressure.If the suction cup opening area (determined by diameter D,D₁) is toolarge, air may not be evacuated fast enough to create the pressuredifferential needed to produce adequate lifting force. If the suctioncup lip area is too small, a large enough lifting force might not beapplied for larger/heavier object no matter what the pressuredifferential. As described herein, the suction cup opening area refersto the area determined by the inner diameter D,D₁ of the flexible cupsection 105,205.

The suction cups employing smaller openings attempt to be as efficientas possible (i.e., lowest power consumption) and employ smaller flowopenings (on the order of ½ inch or smaller) according to a lower flowrate (about 10 scfm, or at most 40 scfm) (scfm=standard cubic feet perminute) and thus can only efficiently/consistently pick up smoothsurface objects. Further, the flow rate through the smaller cup openingis limited, that is, the smaller ½ inch opening suction cup cannotachieve a higher flow rate, no matter the vacuum pressure applied, dueto limitations allowed by air speed from subsonic to supersonic aschoked flow ensues.

In contrast to other systems employing smaller openings and lower flowrates, certain embodiments described herein may provide a higher desiredflow rate, e.g., a high subsonic vacuum air flow rate of at least 60scfm, or in a range of 60 scfm to 120 scfm, during free flow when thepick-up apparatus is free from grasping a target object (i.e., no itemis being grasped by the suction cup 100,200) which is achievable throughthe larger flow opening area (determined by A,A₁) and with a ratio ofinlet flow opening area to flexible cup section opening area (ND; A₁/D₁)of at least 0.46, or between 0.36 and 1.44, or between 0.46 and 1.15.Further, in one example, the flow opening area is such that the minimumflow rate (60 scfm) does not produce a ratio of volumetric flow rate toarea which exceeds Mach 0.2, under standard conditions for temperatureand pressure.

As noted, in order to create a lower pressure, more air should beevacuated than is leaked into the cavity of the suction cup.Supplemental methods/systems for closing off the gaps responsible forair leakage are envisioned. FIGS. 22A-B illustrate an embodiment of sucha method/system comprising an alternate suction cup unit 700 iscomprised of a flexible cup section 705 and a connector (inlet section)702 similar to the prior described embodiments. The suction cup unit 700includes a suction cup lip 710 that is formed with a plurality of radialsegments 720 that are fitted with veins 715 that, when filled withpressurized air, cause elongation of a corrugated top surface while thestructure of the lower surface resists elongation. As a result, there isa moment force (bending moment) that will control concavity of theflexible lip section and force the lip of the suction cup to conformmore closely to the irregular surfaces of the target object.

FIG. 22A illustrates the veins 715 in the non-pressurized state wherebythe radial segments 720 are arranged in a first position with arelatively flat concavity. FIG. 22B illustrates the veins in apressurized state applying the bending moment to move the radialsegments into second position of a greater concavity. This design may beoperable to further close off air gaps and increase the lifting forcegenerated by a given vacuum source, allowing better suction cupperformance on a wider range of irregularly-shaped target objects.

Table A below provides vacuum pump data for an example vacuum pumpsuitable for use in the present system, the pump being a model piClassicavailable from Piab USA, Inc. of Hingham, Mass.

TABLE A Vacuum Pump Vac Pump piClassic Cartridges si32-3 × 6 V-Flow,inHG Vacuum Flow SCFM 0  61.00 3  37.90 6  31.40 9  21.60 12  11.40 15  7.63 22.1 0  

The vacuum pump may provide a relatively high vacuum level such as atleast 16 inHG at zero air flow. To further accommodate the higher airflow rate, in an embodiment, the supply lines 18-22, 38-42 and 60 alsohave large (internal) diameter.

As a supplement (i.e., in conjunction with) or stand-alone, the graspingmechanism may comprise a mechanical device that pierces target objectsto control and manipulate them. One such application of this designincludes three primary features; a pointed flute/spike, an objectcontactor, and a ridged work surface. FIGS. 13-14 are diagrammatic viewsof an alternate object grasping mechanism according to an embodimentusing a piercing mechanism and part stop (object contactor). As shown inFIG. 13 , a target object 320, shown as for example a plastic bottle, ispinned between a weighted part stop 310 and a conveyor 315 (oroptionally ridged work surface). In this state, movement (e.g., axialrotation) of the object 320 is constrained allowing a flute/spike 302 topenetrate the object 320. The flute 302 embeds in such a way that littleor no material is removed from the object 320 and once insertedfrictional forces allow manipulation of the object 320.

In one embodiment, the flute 302 includes a proximal end 304 attached toa drive/support mechanism of a robotic arm (as in a prior embodiment), apointed distal end 308 for piercing the object 320, and a knurled orthreaded end section 306 extending from the center to the pointed distalend 308. While the object 320 is pinned against the work surface 315,the flute 302 may be inserted into the object 320, the pointed distalend 308 piercing the wall of the object. The end section 306 mayoptionally comprise a spiral thread or threaded knurl section, and theflute 302 may then be axially rotated (in a first direction) duringinsertion into the object 320. Once inserted, the end section 306provides a friction connection enabling the object to be lifted off thework surface 315 (and held against the part stop 310) and manipulated toa desired position for ejection. To eject or deposit the object 320, asshown in FIG. 14 , the flute 302 is retracted into the part stop 310whereby the object 320 falls by gravity into a sorting bin or otherlocation. Optionally, the flute 302 may be counter-rotated (axiallyrotated in a second/opposite direction) during retraction in theembodiment where the flute 302 includes a spiral (e.g., a high pitchhelix thread) or threaded knurl. FIG. 14 shows the process for releasingthe object, where the part stop 310 applies a force to the object 320and the (threaded) flute 302 reverses rotation and draws out of theobject, thereby releasing the impaled object 320.

FIG. 15 is a diagrammatic view of an alternate grasping mechanism 400 ofa combination mechanical piercing mechanism (or impaling device) 402(similar to the piercing mechanism 302 as in FIGS. 13-14 ) and (highflow) suction cup 410 (similar to the suction cup 100 as in FIGS. 5-8 orthe suction cup unit 200 as in FIGS. 9-12 ). FIG. 15 shows the piercingmechanism 402 paired with a high flow suction cup 410, in thisembodiment, the piercing mechanism (shown as a pierced spike) 404includes a proximate end section 404, a knurled or spiral fluteinsertion section 406 and a pointed distal end 408. The pierced spike404 supplements the holding force of the vacuum applied by the suctioncup 410 and adds shear resistance (via the knurled/spiral fluteinsertion section 406) to the object 320 which may allow for higheracceleration and faster transport of the object 320 from the conveyor315.

FIGS. 16-18 illustrate a system of manipulating an object or group ofobjects with the use of a finger-like/arm mechanism 500actuating/pivoting in swinging manner to pinch, pierce and/or cradle theobject. The arm mechanism 500 includes three arm units 520, 530, 540arranged/spaced at 120° around the cup mechanism 510. The first arm unit520 includes a first arm section 522 and a second arm section 524, afirst elbow/hinge 526 for allowing articulation/pivoting between thefirst arm section 522 and the support plate 519, and a second elbow 528(optionally a hinge allowing articulation/pivoting) connecting the firstarm section 522 and the second arm section 524. The second arm section524 is shown having a pointed distal end 525 for allowing a point orpiercing contact with the object. The second arm unit 530 includes afirst arm section 532 and a second arm section 534, a first elbow/hinge536 for allowing articulation/pivoting between the first arm section 532and the support plate 519, and a second elbow 538 (optionally a hingefor allowing articulation/pivoting) connecting the first arm section 532and the second arm section 534. The second arm section 534 is shownhaving a pointed distal end 535 for allowing a point or piercing contactwith the object. The third arm unit 540 includes a first arm section 542and a second arm section 544, a first elbow/hinge 546 for allowingarticulation/pivoting between the first arm section 542 and the supportplate 519, and a second elbow 548 (optionally a hinge for allowingarticulation/pivoting) connecting the first arm section 542 and thesecond arm section 544. The second arm section 544 is shown having apointed distal end 545 for allowing a point or piercing contact with theobject. The arm units 520, 530, 540 are arranged and separated at 120°from each other so as to grasp the object in a suitable pinching motion.Releasing the object is achieved by forcing/moving the arms back to theopen position. Grasping and handling of the object may be done withoutregard for the preservation of the target object.

FIG. 19 depicts a combination system 500A including both the armmechanism 500 (of FIGS. 16-18 ) paired with a high flow vacuum cupmechanism 510 with an internal screen 514 (such as the cup mechanismsdescribed in certain prior embodiments).

FIGS. 20A-C illustrate a mechanism 600 for relocating or manipulatingobjects (such as target object 615) in a given space by means of impact,flipping, or nudging the target object, or group of objects being movedalong a conveyor 605. This object relocation is achieved without theneed for directly grasping the object. FIGS. 20A-C show one suchembodiment operating via a precisely directed high-speed impact of amoving/impacting element 610 onto the target object 615, thus generatingsufficient kinetic energy to displace the target object from itsoriginal position to a new desired location. A similar method isenvisioned as a second application, by contacting the object at asynchronous speed and accelerating in such a manner to flip the targetobject to a new location.

FIGS. 21A-C illustrate another embodiment for manipulating objectscomprising a system/method for nudging a moving target object 665 offits current trajectory (being moved along via a conveyor 655), resultingin a two dimensional displacement of the object 665. This nudging may beachieved using a stationary or relatively slow-moving rigid body 660 todeflect the moving target object 665 off its current trajectory,relocating it in space. This methodology may be applied to the object665 more than once, or until the desired final position is satisfied.This process of multiple, slight (incremental) deflections may provide acumulative effect of segregating desired materials from their originalco-mingled stream of miscellaneous objects.

Other embodiments are envisioned. Although the description abovecontains certain specific details, these details should not be construedas limiting the scope of the invention, but as merely providingillustrations of some embodiments/examples. It should be understood thatsubject matter disclosed in one portion herein can be combined with thesubject matter of one or more of other portions herein as long as suchcombinations are not mutually exclusive or inoperable.

The terms and descriptions used herein are set forth by way ofillustration only and not meant as limitations. It will be obvious tothose having skill in the art that many changes may be made to thedetails of the above-described embodiments without departing from theunderlying principles of the inventions.

The invention claimed is:
 1. A vacuum pick-up apparatus usable in amaterial handling system, the vacuum pick-up apparatus comprising: avacuum pump system operable for applying a vacuum air flow; a suctionhead including a flexible suction cup, the suction head operably coupledto the vacuum pump system and receiving the vacuum air flow from thevacuum pump system, the vacuum air flow passing through the flexiblesuction cup and drawing an object into contact with the flexible suctioncup; and a mechanical piercing mechanism operable for moving inconjunction with the flexible suction cup, the mechanical piercingmechanism piercing into the object contacting the flexible suction cupto assist in manipulating the object, wherein the mechanical piercingmechanism is rotatable relative to a rotational axis in a firstdirection when piercing into the object, and rotatable relative to therotational axis in a second opposite direction for releasing the object.2. A vacuum pick-up apparatus according to claim 1, wherein themechanical piercing mechanism extends through the flexible suction cup.3. A vacuum pick-up apparatus according to claim 1, wherein themechanical piercing mechanism includes a pointed insertion section forpiercing into the object.
 4. A vacuum pick-up apparatus according toclaim 3, wherein the pointed insertion section is threaded to add shearresistance to the object.
 5. A vacuum pick-up apparatus according toclaim 1, further comprising one or more movable arms operably coupled tothe suction head and mechanical piercing mechanism, wherein the one ormore movable arms drive the suction head and mechanical piercingmechanism to transport the object contacting the flexible suction cupand grasped by the mechanical piercing mechanism.
 6. An apparatus usablein a material handling system for manipulating an object, the apparatuscomprising: a drive; a mechanical piercing mechanism including a bodywith a first end coupled to the drive and an opposite pointed second endfor piercing the object, wherein the drive is operable to rotate themechanical piercing mechanism relative to a rotational axis and axiallymove the mechanical piercing mechanism relative to the target object forpiercing into the object; and a weighted member axially movable relativeto the piercing mechanism, the weighted member contacting an exteriorsurface of the object to restrain the object from movement prior to themechanical piercing mechanism piercing the exterior surface and into theobject, wherein the mechanical piercing mechanism retains the exteriorsurface of the object against the weighted member while the object ismanipulated.
 7. An apparatus according to claim 6, wherein themechanical piercing mechanism is rotatable relative to the rotationalaxis in a first direction when piercing into the object, and rotatablerelative to the rotational axis in a second opposite direction forreleasing the object.
 8. An apparatus according to claim 6, wherein themechanical piercing mechanism extends through the weighted member whenpiercing the object.
 9. An apparatus according to claim 8, wherein theweighted member is operable to oppose movement of the object when theobject is released.
 10. A vacuum pick-up apparatus according to claim 8,wherein the mechanical piercing mechanism retracts into the weightedmember to release the object.
 11. A vacuum pick-up apparatus accordingto claim 10, wherein the mechanical piercing mechanism is rotated duringretraction into the weighted member.
 12. A vacuum pick-up apparatusaccording to claim 6, further comprising: a vacuum pump system operablefor applying a vacuum air flow; and a suction head including a flexiblesuction cup, the suction head operably coupled to the vacuum pump systemand receiving the vacuum air flow from the vacuum pump system, thevacuum air flow passing through the flexible suction cup and drawing theobject into contact with the flexible suction cup.
 13. A vacuum pick-upapparatus according to claim 6, wherein the pointed second end isthreaded to add shear resistance to the object.
 14. A vacuum pick-upapparatus according to claim 6, wherein the weighted member applies aforce to the object, and wherein the mechanical piercing mechanismrotates and draws out of the object to release the object from theweighted member.
 15. An apparatus usable in a material handling system,the apparatus comprising: a suction head including a flexible suctioncup; a vacuum pump system operable for applying a vacuum air flowthrough the flexible suction cup of the suction head and drawing anobject into contact with the flexible suction cup; and a mechanicalpiercing mechanism comprising a plurality of pivoting arms, eachpivoting arm having a pointed send, the pivoting arms being pivoted tomanipulate the object via the pointed ends piercing into the targetobject.
 16. An apparatus according to claim 15, wherein one or more ofthe pivoting arms pierces the target-object.
 17. An apparatus accordingto claim 16, wherein one or more of the pivoting arms stabilizes theobject that has been pierced.
 18. A vacuum pick-up apparatus accordingto claim 15, wherein one of the pivoting arms extends through theflexible suction cup.
 19. A vacuum pick-up apparatus according to claim15, wherein at least one of the pivoting arms includes a first armsection and a second arm section coupled together via a hinge forfacilitating articulation of the first and second arm sections of the atleast one pivoting arm.
 20. A vacuum pick-up apparatus according toclaim 15, further comprising a support plate, wherein each of thepivoting arms is coupled to the support plate, and wherein each of thepivoting arms further includes: a first arm section and a second armsection; a first hinge coupling the first arm section to the supportplate for facilitating articulation of the first arm section relative tothe support plate; and a second hinge coupling the first and second armsections together for facilitating articulation of the first and secondarm sections.